48in, 52in, or 60in Blower and Drive Kit

1. Park the machine on a level surface.

2. Move the motion-control levers to the NEUTRAL-LOCK position.

3. Engage the parking brake.

4. Shut off the engine and remove the key.

Figure 3

Note: Clean the area around the belt cover before removing it.

1. Lower the mower deck to the lowest height-of-cut position.

2. Remove the right belt cover (Figure 4).

   

   Figure 4

3. Remove the right belt-cover bracket, 2 washers (60-inch mower deck only), and 2 flange nuts from the mower deck (Figure 5).

   Note: Retain the hardware that you removed during this procedure so that it is available for changeover.

   

   Figure 5

   1. Right belt-cover bracket
   2. Washers-only on 152 cm (60 inch) mower deck
   3. Flange nuts

4. Remove the locknut, bolt, spring, and spacer securing the deflector to the pivot brackets (Figure 6).

   

   Figure 6

   1. Bolt
   2. Spacer
   3. Locknut
   4. Spring
   5. Spring installed
   6. Grass deflector
   7. J-hook end of spring

5. Remove the grass deflector (Figure 6).

Parts needed for this procedure:

1. On the machine, remove the spring tension from the spring-loaded idler pulley; refer to Figure 7 or Figure 9.

   Note: For blower Models 78401, 78402, and 78403, use the spring-removal tool (Toro Part No. 92-5771) to remove the spring from the mower-deck post (Figure 8).

   Note: For blower Models 78404, 78405, and 78406, use a ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 9).

   

   Figure 7

   For Models 78401, 78402, and 78403

   1. Clutch pulley
   2. Mower belt
   3. Spring-loaded idler pulley
   4. Spring
   

   Figure 8

   For Models 78401, 78402, and 78403

   1. Spring-removal tool (Toro Part No. 92-5771)
   2. Idler spring
   3. Mower-deck post
   4. Idler arm
   5. Mower belt
   

   Figure 9

   For Models 78404, 78405, and 78406

   1. Clutch pulley
   2. Mower belt
   3. Spring-loaded idler pulley
   4. Ratchet
   5. Square hole in the idler arm for the ratchet

2. Remove the belt from the right mower-deck pulley.

3. Use a wrench (1-1/2 inches) to hold the spindle shaft, as you remove the locknut (3/4 inch) and washer from the spindle shaft (Figure 10).

   Note: Set aside the locknut (3/4 inch) and washer for blower Models 78404, 78405, and 78406.

   

   Figure 10

   1. Locknut (3/4 inch)
   2. Washer
   3. Right spindle shaft

4. Use a wrench (1-1/2 inches) to hold the spindle shaft, as you install the double pulley onto the right spindle shaft.

   • For blower Models 78401, 78402, and 78403, perform the following procedure:

     1. Use the locknut (3/4 inch) and washer to secure the new double pulley onto the right spindle shaft (Figure 11).

     2. Torque the locknut (3/4 inch) to 176 to 217 N∙m (130 to 160 ft-lb).

     

     Figure 11

     1. Locknut (3/4 inch)
     2. Washer
     3. Double pulley
     4. Right spindle shaft

   • For blower Models 78404, 78405, and 78406, perform the following procedure:

     1. Insert the threaded studs on pulley mount through the holes in the deck pulley (Figure 12).

     2. Use the locknut (3/4 inch) and washer that you set aside earlier to secure the deck pulley to the spindle shaft (Figure 12).

     3. Torque the locknut (3/4 inch) to 176 to 217 N∙m (130 to 160 ft-lb).

     4. Arrange the blower pulley onto the threaded studs and loosely install the locknut (Figure 12).

     5. Rotate the blower pulley clockwise until it stops.

     6. Torque the 3 locknuts to 18 N∙m (13 ft-lb).

     

     Figure 12

     1. Locknut (3/8 inch)
     2. Blower pulley
     3. Locknut (3/4 inch)
     4. Washer
     5. Existing deck pulley
     6. Pulley mount
     7. Right spindle shaft

5. Ensure that the blade bolt is torqued to 115 to 149 N∙m (85 to 110 ft-lb).

6. Install the mower belt around the lower pulley of the double pulley (Figure 13).

   

   Figure 13

   1. Lower pulley
   2. Mower belt

7. Install the belt-cover bracket to the mower deck using 2 carriage bolts (1/4 x 3/4 inch) and 2 locknuts (1/4 inch) as shown in Figure 14.

8. Install the speed nut onto the belt-cover bracket (Figure 14).

   

   Figure 14

   1. Carriage bolt (1/4 x 3/4 inch)
   2. Belt-cover bracket
   3. Speed nut
   4. Locknut (1/4 inch)

9. Install the mower deck belt around the spring-loaded idler pulley (Figure 7 or Figure 9).

10. Use the spring-removal tool (Toro Part No. 92-5771) to attach the spring to the spring-loaded idler pulley.

Parts needed for this procedure:

1. Remove the 2 existing flange nuts (3/8 inch) and 2 carriage bolts (3/8 x 7/8 inch) from the mower deck (Figure 15).

   

   Figure 15

   1. Flange nut (3/8 inch)
   2. Carriage bolt (3/8 x 7/8 inch)

2. Install the baffle using the carriage bolt (5/16 x 7/8 inch), flange nut (5/16 inch), 2 carriage bolts (3/8 x 7/8 inch), and 2 flange nuts (3/8 inch) as shown in Figure 16.

   

   Figure 16

   1. Flange nut (3/8 inch)
   2. Carriage bolt (3/8 x 7/8 inch)
   3. Baffle
   4. Flange nut (5/16 inch)
   5. Carriage bolt (5/16 x 7/8 inch)

Parts needed for this procedure:

Verify that the pivot pin is secured on the blower assembly in the correct location (Figure 17).

• If you have a 48-inch or 52-inch mower deck, install the pivot pin in the front hole (Figure 17).

• If you have a 60-inch mower deck, install the pivot pin in the rear hole (Figure 17).

Figure 17

Blower for 48-inch and 52-inch mower deck shown

1. Blower assembly
2. Front hole (48-inch and 52-inch mower deck)
3. Rear hole (60-inch mower deck)
4. Pivot pin
5. Roll pin

1. Align the pivot pin on the blower with the pivot-pin hole in the mower deck (Figure 18).

   

   Figure 18

   1. Blower assembly
   2. Blower-pivot pin
   3. Pivot hole
   4. Deck

2. Install the belt around the pulleys inside the blower (Figure 19).

   

   Figure 19

3. Lower the blower and slide the pivot pin into the pivot hole (Figure 18).

   Note: Ensure that the belt remains positioned in the blower pulley.

4. Move the latch pin from the locking position to the open position (Figure 20).

   

   Figure 20

   1. Latch pin
   2. Chute bracket
   3. Idler-pivot bracket
   4. Idler pulley
   5. Belt (beneath the idler pulley)
   6. Blower assembly

5. Close the blower assembly and align the latch pin with the hole in the chute bracket (Figure 20).

6. Move the latch pin to the locking position.

   Note: Ensure that the latch pin extends through the hole in the chute bracket.

   Note: Ensure that the latch firmly holds the blower assembly against the mower deck, but you can release it by hand.

Parts needed for this procedure:

1. Pull back the spring-loaded idler pulley and route the blower belt around the drive pulley (Figure 21).

   

   Figure 21

   1. Blower belt
   2. Drive pulley

2. Install the blower-belt cover over the blower belt and secure the blower-belt cover with the knob (Figure 22).

   

   Figure 22

   1. Knob
   2. Belt cover